Bolt-Together Frame

ABSTRACT

The present invention relates to a structural rack comprising at least two spaced end assemblies. The rack comprises at least one shelf positioned between and connected to each end assembly. In one aspect, each end assembly comprises a first and second spaced, substantially upright, elongate columns. The columns may be positioned such that the front face of the first elongate column is substantially facing the front face of the second elongate column. In one aspect, a plurality of integrally formed, spaced studs extends therefrom the front face of each of the columns. In another aspect, each end assembly comprises a plurality of diagonal cross members configured to connect to a stud on the first elongate column and to a stud on the second elongate column.

FIELD OF THE INVENTION

The present invention pertains to bolt-together frame. In particular, it pertains to a bolt-together frame for racking systems used in warehouse shelving applications.

BACKGROUND OF THE INVENTION

In the material handling industry, it is necessary to pre-build racking systems for warehouses that are capable of holding pallets of materials. The racking systems generally comprise posts, reinforcement supports, and shelves. Generally, the posts and reinforcement supports are fabricated prior to shipment, while the shelves and supports for the shelves are attached in the field.

In one example, the posts and reinforcement supports are welded together at the fabrication facility and then are shipped to the installation location. This is quite costly as each unit is heavy and large. An alternative to this scenario is to ship the posts and supports separately and fabricate them at the installation location. The problem with this scenario is that it requires the extensive use of in the field labor, which is generally more expensive. What is needed is a solution that enables the shipment of the components separately, while keeping the fabrication costs in the field to a minimum.

SUMMARY

In one embodiment, the present invention relates to a structural rack comprising at least two spaced end assemblies. The rack comprises at least one shelf positioned between and connected to each end assembly. In one aspect, each end assembly comprises a first and second spaced, substantially upright, elongate column. The columns may be positioned such that the front face of the first elongate column is substantially facing the front face of the second elongate column.

In one aspect, a plurality of integrally formed, spaced studs extends from the front face of each of the columns. The integral studs may, for example, be spaced evenly along the longitudinal length of the elongate column. In another aspect, each end assembly comprises a plurality of diagonal cross members, wherein a proximal end of each diagonal cross member is configured to connect to a stud on the first elongate column and a distal end of each diagonal cross member is configured to connect to a stud on the second elongate column.

DETAILED DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate certain aspects of the instant invention and together with the description, serve to explain, without limitation, the principles of the invention. Like reference characters used therein indicate like parts throughout the several drawings.

FIG. 1 is a perspective view of one aspect of the present invention for a structural rack.

FIG. 2 is an exploded and fragmented perspective view of an end assembly of the rack of FIG. 1, showing horizontal and diagonal cross members.

FIG. 3 is a transverse elevational view of an end assembly of the rack of FIG. 1.

FIG. 4 is an enlarged detail view taken at inset circle 4 in FIG. 3.

FIG. 5 is a transverse elevational view of an end assembly of an alternate embodiment of a structural rack according to the present invention.

FIG. 6 is an enlarged detail view taken at inset circle 6 in FIG. 5.

FIG. 7 is a transverse elevational view of an end assembly of an alternate embodiment for the structural rack of the present invention.

FIG. 8 is an enlarged detail view taken at inset circle 8 in FIG. 7.

DETAILED DESCRIPTION OF THE INVENTION

The present invention may be understood more readily by reference to the following detailed description of the invention and the Examples included therein and to the Figures and their previous and following description.

Before the present systems, articles, devices, and/or methods are disclosed and described, it is to be understood that this invention is not limited to specific systems, specific devices, or to particular methodology, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

The following description of the invention is provided as an enabling teaching of the invention in its best, currently known embodiment. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the invention described herein, while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present invention are possible and can even be desirable in certain circumstances and are a part of the present invention. Thus, the following description is provided as illustrative of the principles of the present invention and not in limitation thereof.

As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a rack” includes two or more such racks, and the like.

Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

“Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

In one embodiment of the present invention, the present invention relates to a structural rack 10 comprising at least two spaced end assemblies 100. As can be seen in FIG. 1, each rack 10 comprises at least one shelf positioned between and connected to each end assembly 100. As one skilled in the art will appreciate, a structural rack 10 may contain many end assemblies 100 connected together and supported by one or more shelves 200. Some end assemblies may also be intermediate other end assemblies. The rack may be, for instance, at least partially manufactured using structural steel.

In one aspect, each end assembly has a first and second spaced, substantially upright, elongate column 110. The columns 110 may be positioned such that the front face 120 of the first elongate column is substantially facing the front face 120 of the second elongate column. The columns may also be formed from structural steel. As one skilled in the art will appreciate, the elongate columns may be hot formed, however, they may also be cold-rolled. As one skilled in the art will appreciate, the width of the end assemblies (or the depth of the rack) can vary from installation to installation. However, for most cases the width of the end assemblies 100 ranges from between about 30 and 72 inches. Additionally, the column (or rack) height may also vary, depending upon the installation. In general, column height can range from between about 8 to 60 feet.

In one aspect, a plurality of integrally formed, spaced studs 130 extends from the front face of each of the columns 110. One advantage of having the studs integrally formed is that the head of the stud or bolt does not protrude from the back face of the elongate column, which could cause a potential obstruction. In one aspect, integrally forming the studs 130 provides a substantially even surface to which a clip, bracket, or other fastener may be attached.

The integral studs maybe, for example and not meant to be limiting, spaced evenly along the longitudinal length of the elongate column 110. In one aspect, the studs are spaced evenly along the longitudinal length of the middle portion of the elongate column. In yet another aspect, at least one stud comprises a threaded exterior surface. One would appreciate that threading the surface of the integral stud facilitates attaching a fastener onto the stud.

In another aspect, each end assembly comprises a plurality of diagonal cross members 140. As such, a proximal end 142 of each diagonal cross member is configured to connect to a stud on the first elongate column and a distal end 144 of each diagonal cross member is configured to connect to a stud on the second elongate column. In one exemplary aspect, when situated between the two elongate columns, the diagonal cross member 140 is not perpendicular to either the first or the second elongate column.

In a further aspect of the rack 10, each spaced end assembly comprises horizontal cross members 150. In this aspect, a proximal end 152 of each horizontal cross member is configured to engage a stud on the first elongate column and a distal end 154 of the horizontal cross member is configured to engage a complimentary stud 130 on the second elongate column. When situated between the two elongate columns, each horizontal cross member 150 is positioned substantially perpendicular to the respective first and second elongate columns 110. As one skilled in the art will appreciate, the spacing between adjacent horizontal cross members 150 may vary, depending upon the load of the rack. In most cases, the spacing between adjacent horizontal cross members can range between about 18 and 72 inches. In another aspect, the horizontal and vertical cross members can comprise thin walled pipe, which ranges in diameter from between about ½ to 2 inches.

The end assemblies may be configured in various fashions. For instance, they may be configured with “K” braces, where diagonal cross members 140 alternate in direction, such as in FIG. 5. A “Z” brace configuration, such as in FIGS. 1, 2, and 3, or a truss configuration, where there are no diagonal cross members (not shown), may also be used. As one skilled in the art will appreciate, other brace configurations are also contemplated.

In still another aspect, the structural rack comprises at least one shelf positioned between and connected to each of the two spaced end assemblies. It is preferable to provide more than one shelf, as the shelves 200 keep the end assemblies 100 in the substantially upright position. Each shelf is configured to support a load of product, either on pallets or not. In one aspect, the first elongate column is substantially parallel to its respective second elongate column.

Although the columns may be substantially any cross-sectional shape, such as, for example, C-shape, L-shape, I-shape or tubular shape, in one aspect, each of the elongate columns comprises a pair of integrally formed opposed flanges 160 extending outwardly away from a portion of the front face, as shown in FIG. 1. In another aspect, the flanges 160 extend along at least a portion of the longitudinal length of each of the elongate columns.

Although several aspects of the invention have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other aspects of the invention will come to mind to which the invention pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the invention is not limited to the specific aspects disclosed hereinabove, and that many modifications and other aspects are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims which follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention. 

1. A structural rack comprising: a) at least two spaced end assemblies, each end assembly comprising: i) a first and second spaced, substantially upright, elongate columns, each column having a front face and an opposed back face, wherein the first and second elongate columns are positioned such that the front face of the first elongate column is substantially facing the front face of the second elongate column; ii) a plurality of integrally formed, spaced studs extending therefrom the front face of each of the first and second elongate columns; iii) a plurality of diagonal cross members, wherein a proximal end of each diagonal cross member is configured to connect to a stud on the first elongate column and a distal end of each diagonal cross member is configured to connect to a stud on the second elongate column such that the diagonal cross member is not perpendicular to either the first or the second elongate column; and b) at least one shelf positioned between and connected to each of the two spaced end assemblies.
 2. The rack of claim 1, wherein the first elongate column is substantially parallel to its respective second elongate column.
 3. The rack of claim 1, wherein each of the elongate columns further comprises a pair of integrally formed opposed flanges extending outwardly away from a portion of the front face.
 4. The rack of claim 3, wherein the flanges extend along at least a portion of the longitudinal length of each of the elongate columns.
 5. The rack of claims 3 or 4, the each flange extends above the front face an equal distance.
 6. The rack of claim 1, wherein each of the elongate columns comprises a substantially C-shaped cross-section.
 7. The rack of claim 1, wherein each of the elongate columns comprises a substantially L-shaped cross-section.
 8. The rack of claim 1, wherein each of the elongate columns comprises a substantially I-shaped cross-section.
 9. The rack of claim 1, wherein each of the elongate columns comprises a substantially tubular shape.
 10. The rack of claim 1, wherein the elongate columns comprise structural steel.
 11. The rack of claim 1, wherein at least a portion of the plurality of studs are spaced evenly along the longitudinal length of the elongate column.
 12. The rack of claim 1, wherein the elongate columns comprise a middle portion and wherein the plurality of studs is spaced evenly along the longitudinal length of the middle portion.
 13. The rack of claim 1, wherein at least one stud comprises a threaded exterior surface.
 14. The rack of claim 1, wherein each spaced end assembly further comprises horizontal cross members, wherein a proximal end of each horizontal cross member is configured to engage a stud on the first elongate column and wherein a distal end of the horizontal cross member is configured to engage a complimentary stud on the second elongate column such that each horizontal cross member is substantially perpendicular to the respective first and second elongate columns. 